Just over a week agao I found that my Macbook wasn’t charging, but the charger was plugged in and on. I inspected the cable and found that it had melted just outside of the transformer!
I temporarily fixed it with some blue insulation tape, but today, it failed all together 
I have already ordered one off of eBay, ordered on Tuesday and dispatched the following day. Should hopefully be here anytime soon.
In the mean time, I have fixed the transformer 
A fair bodge job, but it seems to work now.
Prior to the work, I spent about an hour trawling the internet for a how-to, couldn’t find one, so here’s my own.
My burnt area was right up close to the transformer, so I needed to get in to sort out this problem. First, I cut the wire close to the transformer, so the magsafe adaptor is connected to the wire and burnt/damaged wire. 
I then set about forcing off the little clips the pop out enabling you to wrap up the cable. I couldn’t find a way of preserving these, so they were snapped off. Also, snap out the little metal clip which makes them springy.
After this, I needed to break into the casing. This is hard as it seems to be one, moulded unit. So I forced the rubbery flex protector where the little stub of cable clinged and managed to fish out the rubber material. I then had several holes into the case. To get the case open ‘simply’ take a screw driver and a hammer (that can’t be good?), then chisel away at the plastic in the gap. After about two hours, you should have chipped through the casing. Well done! You will hear cracking as you chip away. Don’t be worried!
With the case off, you will see the little transformer, wrapped in copper, guessing this is to dissipate the heat. You can carefully unwrap the copper plates, and slide out the inner board. With the top exposed, you can
nip away at the white and black wires just at the base of the last of the rubbery flex protector.
White is the core, black is the shield, terms may be wrong, but essentially, the white wire will be connected to the innermost set of cables, and the the black wire will be connected to the outer cables.
Now, some of my crap soldering. I soldered the core first, then the shield. I wrapped some insulation tape around the core so that the connections didn’t touch.
Wrap the copper casing back around the board, I taped it down with some more insulating tape. Carefully putting everything back into the case, I then put loads of insulating tape around the case to keep it all together!
lol that’s pretty crazy, good job on bodge/fixing it though – im impressed!
You could at least have used white insulating tape
Bit of tipex could sort that out though!
I am rather impressed fair play.
I had the same problem on my adapter, but at the other end of the cable. Luckily, it was still guaranteed at the time so Apple replaced it.
I love the look of this fix though, very stylish.
Lmao! Take that macs XD What the hell kinda technology just up and melts on you?
But seriously – amazing fix job man XD Proper manly work with breaking things and taping them back together ect. I’m proud of you
I have exactly the same problem now. I will try to follow your instructions. Man I wish this would work. It seems not so easy though.
J
JP,
The worst part is cracking open the case, you just hear splintering plastic and it’s very hard to get into…
After that, it’s just like joining any two pieces of wire together…
Post back to say how it went
Ben
So glad i found this, my bunny chewed half way through my macbook air charger last night, luckily it was the 14v side not the 240v side! Right at the same place urs has melted, iv opened the casing with a knife didnt have to chip or use much force at all, got it working with insulatin take round the bitten bit at the moment but i dont trust it lol hope my house isnt on fire when i get home. Il repair it properly now iv found this though!
Well i done it
Clicky1
This was the bunny damage!
So i sliced the little connector that surrounds the cables, and pealed the cables out.
Clicky2
Cut the cables and twisted and soldered them back together, covered them in shrink wrap sleeve, then put the wires back into the small outlet bung, and run the soldering iron over the cut to seal it back up!
Clicky3
I then stuck bother halvs back together with Araldite (like super duper glue), left it to set and now it looks as good as new!!
Thanks so much for your original article! Gave me the ballz to do it!
Adam
Congratulations! A much neater job than mine!
I’m glad, and a little peeved, that you managed to open the casing with such little damage, I spent a good two hours with a screwdriver and a hammer…
I’m glad that my article helped
Ben
its much easier and shorter not to crack the case with the hammer, but with a dremel at the plastic in the gap, it tooks me about 3 minutes, thank you very much, the rest of the procedure identically!!!!
extraordinary article!!!